Optimization Of Minimum Quantity Lubrication In Grinding With Cbn Wheels

The application of minimum quantity lubrication (MQL) to metal machining has emerged as an alternative means to reduce cutting fluid usage, leading to cleaner production. In grinding, although MQL is considered to be progress regarding the environment, its application is restricted due to excessive heat generation and wheel clogging, which reduce final product quality and increase tool wear. 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Cerâmicas avançadas no processo de retificação cilíndrica externa de mergulho utilizando a técnica da mínima quantidade de lubrificação (MQL) com rebolos diamantados

Nas últimas duas décadas, as cerâmicas avançadas têm sido exaustivamente utilizadas em aplicações na indústria devido às suas propriedades de elevada resistência ao desgaste e dureza. Entretanto, ainda se tem um alto custo agregado ao acabamento da peça. Esse acabamento geralmente é feito pelo processo de retificação, único processo economicamente viável que produz superfícies de elevada qualidade e precisão geométrica. Nesse contexto, as empresas vêm buscando a otimização no processo de retificação como, por exemplo, a redução do fluxo de fluido de corte utilizado, o que também visa atender exigências mundiais de preservação ambiental. Desta forma, este projeto pretendeu explorar a técnica da Mínima Quantidade de Lubrificação (MQL) na retificação cilíndrica externa de mergulho em cerâmicas com rebolos diamantados. Foram utilizados dois métodos de refrigeração: o convencional e o MQL, com três avanços de corte para cada caso. Foram usados um bocal convencional e um bocal para o MQL, tendo este um uniformizador de saída do jato. Foram analisadas como variáveis de saída: a emissão acústica, relação G, aspecto da superfície via microscopia eletrônica de varredura (MEV), rugosidade e circularidade. Assim, embora a refrigeração convencional ainda apresente os melhores resultados em comparação com a refrigeração com MQL, esta última pode atender os requisitos necessários para diversas aplicações, em especial quando utilizadas baixas espessuras equivalentes de corte (h eq). Além disso, a técnica de MQL possui a vantagem de gerar um menor impacto ambiental em comparação com a lubrificação convencional, devido ao uso mínimo de fluido de corte cujo descarte é cada vez mais regulamentado e custoso.Advanced ceramics have been extensively used in applications in industry in the last two decades because of their properties of high resistance to wear and hardness. Nevertheless, the finishing process highly increases the cost of pieces and components. The finishing process is, in most cases, grinding, the only viable process that produces high quality surfaces and guarantees geometric precision. In this context, companies are seeking to optimize the grinding process by, for example, reducing the usage and flow of cutting fluid, which also helps to achieve global environmental preservation requirements. Thus this project sought to exploit the technique of Minimum Quantity of Lubrication of the external cylindrical grinding in ceramics with diamond wheels. The project used two methods of cooling, the conventional and MQL, with three feed velocity in each case. We used a conventional nozzle, a mouthpiece for the MQL the latter having a uniform output of the jet. Variables were analyzed as the output acoustic emission, G relationship, surface condition by scanning electron microscopy (SEM), roughness and circularity. Even though the conventional cooling still achieves better results in some aspects, in comparison with the MQL method, the latest is able to attend the requirements for many applications, especially with lower feed velocities. Furthermore, the MQL method brings environmental benefits, due to its lower consumption, and thus disposal, of cutting fluids